Fabric reinforced cement structure

Abstract

A composite material is composed of a matrix of water hardenable material such as a portland-cement-based mixture, and reinforcement consisting of a plurality of layers of open-mesh textile fabric, each layer including two sets of straight lying parallel textile elements united to form the fabric. The width of the elements in each set is preferably chosen so that there is formed within the reinforcement a plurality of irregular cavities extending throughout the thickness of the reinforcement and filled with material of the matrix to form irregular plugs of the matrix material tending to unite the layers of fabric and distribute stresses between them. The individual textile elements may be monofilaments of various cross-sectional form, spun yarns, bundles, rovings, or composite filaments. The elements of the two sets can be united by wearing, weaving, additional yarns or adhesive.

We claim: 
     
       1. A composite structure comprising a water-hardened matrix and reinforcement comprising a plurality of layers of open mesh textile fabric, each layer of said textile fabric being composed of a plurality of united sets of textile elements, said elements of each said set lying straight and parallel to each other, the spacing between adjacent elements is greater than the widths of each of said elements, and a plurality of irregular cavities extending transversely of and within said reinforcement and containing plugs of said matrix material. 
     
     
       2. A structure as set forth in claim 1, wherein said textile elements are selected from the group consisting of monofilaments, spun yarns, tapes, bundles, rovings, and composite filaments. 
     
     
       3. A structure as set forth in claim 1, wherein said spacing is at least 1.5 times the width of said individual elements. 
     
     
       4. A structure as set forth in claim 3, wherein said spacing is from 2 to 10 times the width of said individual elements. 
     
     
       5. A structure as set forth in claim 4, wherein said spacing is from 5 to 6 times the width of said individual elements. 
     
     
       6. A structure as set forth in claim 1, wherein there are two sets of said elements woven together. 
     
     
       7. A structure as set forth in claim 1, wherein there are two sets of said elements laid one on the other and united by additional means. 
     
     
       8. A structure as set forth in claim 7, wherein said additional means is selected from the group consisting of additional threads; adhesive; and welding. 
     
     
       9. A structure as set forth in claim 1, wherein said textile elements are treated to have a surface capable of bonding with said matrix material. 
     
     
       10. A structure as set forth in claim 1, wherein said textile elements are of polypropylene. 
     
     
       11. A structure as set forth in claim 1, wherein said matrix material is selected from the group consisting of Portland cement, gypsum based cement, pozzolanas, and special cements. 
     
     
       12. A composite material as set forth in claim 1, wherein there is added to said textile reinforcement an additional layer of material comprising a base fabric and a layer of non-woven fibres. 
     
     
       13. A method for forming a composite structure comprising forming a water-hardenable matrix and reinforcement in the form of a plurality of layers of open mesh textile fabric, each layer of said textile fabric being composed of a plurality of united sets of textile elements, said elements of each said set lying straight and parallel to each other.